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INTRODUCTION ...............................................................................................................................Intro-1
VLT® PRODUCT OVERVIEW ........................................................................................................... Intro-1
FOR YOUR SAFETY ......................................................................................................................... Intro-1
ELECTROSTATIC DISCHARGE (ESD) ............................................................................................. Intro-1
TOOLS REQUIRED ........................................................................................................................... Intro-1
Additional Tools Recommended for Testing ............................................................................ Intro-1
i
Table of Contents (continued)
ii
Table of Contents (continued)
iii
List of Figures
Figure Title Page
iv
List of Tables
Table Title Page
v
INTRODUCTION
! DANGER
The purpose of this manual is to provide detailed
technical information and instructions that will enable
a qualified technician to identify faults and perform Drives contain dangerous voltages
repairs on VLT series adjustable frequency drives of when connected to line voltage. Only a
125/150 hp to 300/350 hp, 380 to 480 V. competent technician should carry out
service.
It provides the reader with a general view of the unit's
main assemblies and a description of the internal
FOR YOUR SAFETY
processing. With this information, technicians should
1. DO NOT touch electrical parts of drive
have a better understanding of the drive's operation
when AC line is connected. After AC line
to assist in troubleshooting and repair.
is disconnected wait at least 15 minutes
This manual provides instructions for: before touching any components.
VLT 4000 series 380-460 V VLT 5000 series 380-460 V 2. When repair or inspection is made, AC
line must be disconnected.
VLT 4152 150 hp VLT 5122 125 hp
VLT 4202 200 hp VLT 5152 150 hp 3. STOP key on control panel does not
VLT 4252 250 hp VLT 5202 200 hp disconnect AC line.
VLT 4302 300 hp VLT 5252 250 hp
VLT 4352 350 hp VLT 5302 300 hp 4. During operation and while programming
parameters, motor may start without
VLT 6000 series 380-460 V VLT 8000 AQUA 380-460 V
war ning. Activate STOP key when
VLT 6152 150 hp VLT 8152 150 hp changing data.
VLT 6172 200 hp VLT 8202 200 hp
VLT 6222
VLT 6272
250 hp
300 hp
VLT 8252
VLT 8302
250 hp
300 hp ! CAUTION
VLT 6352 350 hp VLT 8352 350 hp When performing service, use proper
ESD procedures to prevent damage to
These models are available in Chassis, NEMA 1 or sensitive components.
NEMA 12 enclosures.
Control card
PCA1
Power card PCA 3
Main AC power
input terminals
TB1
IGBT module
Fan assembly F1
IGBT1
+ C1 +CBL11
Current sensor
L1, L2, L3
Output motor terminals TB2
Control card
PCA1
Power card
PCA3
Fan fuse
Input terminal mounting plate
FU4
assembly
Fan assembly F1
+ C1 + CBL11
Current sensor
L1, L2, L3
Output motor terminals TB2
Model number VLT 4152 VLT 4202 VLT 4252 VLT 4302 VLT 4352
VLT 5122 VLT 5152 VLT 5202 VLT 5252 VLT 5302
VLT 6152 VLT 6172 VLT 6222 VLT 6272 VLT 6352
VLT 8152 VLT 8202 VLT 8252 VLT 8302 VLT 8352
Normal overload current ratings (110 %):
Output current Nominal [A] (380-440 V) 212 260 315 395 480
MAX (60 sec) [A] (380-440 V) 233 286 347 434 528
Nominal [A] (441-500 V) 190 240 302 361 443
MAX (60 sec) [A] (441-500 V) 209 264 332 397 487
Typical shaft output [kW] (400 V) 110 132 160 200 250
[HP] (460 V) 150 200 250 300 350
[kW] (500 V) 132 160 200 250 315
Output current Nominal [A] (380-440 V) 177 212 260 315 395
MAX (60 sec) [A] (380-440 V) 266 318 390 473 593
Nominal [A] (441-500 V) 160 190 240 302 361
MAX (60 sec) [A] (441-500 V) 240 285 360 453 542
Power loss Normal overload [W] 2619 3309 4163 4977 6107
Power loss High overload [W] 2206 2619 3309 4163 4977
Fan Voltage Low Speed Fan VAC 200 200 200 200 200
Fan Voltage High Speed Fan VAC 230 230 230 230 230
Normal Display
In normal operational mode after start up, the top line
40.0Hz SETUP
1
of the display (line 1) identifies the value displayed in
line 2. The large display (line 2) shows a value, in this RUNNING
case the drive output in hertz. The setup number and
direction of motor rotation is also shown. The bottom
line (line 4) is the status line. This line displays the
current operational status of the drive. The illustration To identify the 3 meters displayed in line 1,
DISPLAY
below indicates that the drive is running at 40 HZ STATUS
press and hold the [DISPLAY/STATUS] key.
output. The identity of the meter is displayed while
the key is pressed.
Line 1 FREQUENCY
Line 2
40.0Hz SETUP
1
REF% TORQ% CURR.A
Line 3
RUNNING
40.0Hz SETUP
1
Line 4
RUNNING
Pressing the up [+] or down [-] keys on the
keypad in this mode changes the data The values displayed in lines 1 and 2 can be
shown in line 2. Thirty-one different programmed from a list of options. See programming
+ diagnostic values are identified (in line 1) and in the operator's manual for details.
displayed (in line 2) by scrolling through the
– display data. Setpoints, feedback,
operational hours, digital and analog input
status, relay output status, and many other
system functions are identified and their
values shown in real-time.
60.0Hz SETUP
1
010 Reference (%)
011 Motor current (A)
012 Power (kW)
009 Frequency (Hz)
DISPLAY DESCRIPTION
DISPLAY DESCRIPTION
OFF1 Stop command (Ramp Down) received via serial communication, and
Fieldbus selected in parameter 512.
OFF2 Stop command (Coast) received via serial communication, and
Fieldbus selected in parameter 512.
OFF3 Stop command (Q Stop) received via serial communication, and
Fieldbus selected in parameter 512.
OVER VOLTAGE Parameter 400, Overvoltage Control, enabled. Drive is attempting to
CONTROL avoid a trip from overvoltage by extending decel ramp time.
QUICK Quick discharge function has been completed successfully.
DISCHARGE OK
REM/BUS JOG1 Remote control selected and Fieldbus selected in parameter 512. Jog
1 command has been given via serial communication.
REM/BUS JOG2 Remote control selected and Fieldbus selected in parameter 512. Jog
2 command has been given via serial communication.
REM/DC STOP Remote control selected and drive stopped via a DC stop signal on a
digital input or serial communication.
REM/LCP STOP Remote control selected and drive is stopped via control panel. Coast
signal on terminal 27 high. Start command via remote digital input or
serial communication is overridden.
REM/QSTOP Remote control selected and drive stopped via a quick-stop signal on
terminal 27 or serial communication.
REM/RAMPING Remote control selected and motor speed and drive output frequency
is changing.
REM/RUN JOG Remote control selected and drive is running at a fixed frequency set
in parameter 213, Jog Frequency via digital input or serial
communication.
REM/RUN OK Remote control selected and motor is running and speed corresponds
to reference.
REM/STOP Remote control selected and drive stopped via control panel, digital
input or serial communication.
REM/UNIT READY Remote control selected and 0 V on terminal 27.
SLOW DOWN Drive output frequency reduced by percentage value selected in
parameter 219, Catch up/Slow down Value.
STAND BY Drive will start when a start signal received via digital input or serial
communication.
START Input on digital inputs and parameter data are in conflict.
FORW./REV
START INHIBIT OFF1, OFF2, OFF3 condition has been rectified. Drive cannot start
until OFF1 bit is toggled (OFF1 set from 1 to 0 then to 1). Fieldbus
selected in parameter 512.
UNIT NOT READY Drive not ready for operation because of a trip or because OFF1,
OFF2 or OFF3 is a logic ‘0.’ (Only on units with external 24 VDC
supply.)
CONTROL POINT
AUTO Drive in Auto mode, which means that Run/Stop control is carried out
remotely via input control terminals and/or serial communication.
HAND Drive in Hand mode, which means that Run/Stop control is carried out
via keys on the keypad.
OFF OFF/STOP activated either by means of keypad or by digital input
terminals.
REFERENCE LOCATION
REM. REMOTE selected, which means reference is set via input control
terminals or serial communication.
LOCAL LOCAL selected, which means reference is set with [+] and [-] keys on
keypad.
DRIVE STATUS
AMA RUN Automatic motor adaptation enabled in parameter 107, Automatic Motor
Adaptation, AMA and drive performing adaptation function.
AMA STOP Automatic motor adaptation completed. Drive is now ready for
operation after Reset enabled. Motor may start after drive reset.
AUTO RAMP Parameter 208, Automatic Ramp, enabled. Drive is attempting to avoid
a trip from overvoltage by extending decel ramp time.
CTR.READY This status only active when a Profibus option card is installed.
DC STOP DC brake enabled in parameters 114 through 116.
FRZ.OUT Drive output frequency frozen at fixed rate from input command.
FRZ.REQ Start command to run at current frequency given but motor will not start
until a Run Permission signal is received via a digital input.
JOG Jog enabled via digital input or serial communication. Drive is running
at a fixed frequency set in parameter 209, Jog Frequency.
JOG REQ. Start command to run at jog frequency given but motor will not start
until a Run Permission signal is received via a digital input.
NOT READY Drive not ready for operation because of a trip or because OFF1, OFF2
or OFF3 is a logic ‘0.’
RAMPING Motor speed and drive output frequency is changing.
RUN REQ. Start command given but motor will not start until a Run Permission
signal is received via digital input.
RUNNING Motor running and speed corresponds to reference.
SLEEP Parameter 403, Sleep Mode Timer, enabled. Motor stopped in sleep
mode. It can restart automatically.
SLEEP.BST Sleep boost function in parameter 406, Boost Setpoint, enabled. Drive
is ramping up to boost setpoint.
STANDBY Drive able to start motor when a start command is received.
START Reversing and start on terminal 19, parameter 303, Digital Inputs, and
Start on terminal 18, parameter 302, Digital Inputs, are both enabled.
Motor will remain stopped until either signal becomes logic ‘0.’
START DEL Start delay time programmed in parameter 111, Start Delay. When
delay time expires, drive will start and ramp up to reference frequency.
START IN. This status only displayed if parameter 599, Profidrive [1] selected and
OFF2 or OFF3 is a logic ‘0.’
STOP Motor stopped via a stop signal from serial communication.
UN.READY Unit ready for operation but digital input terminal 27 is logic ‘0’ and/or a
Coasting Command received via serial communication.
XXXX Control microprocessor stopped for unknown cause and drive not
operating. Cause may be noise on the power line, motor leads or
control wires.
ALARM:12 SETUP
1
WARN.4 SETUP
TORQUE LIMIT
SERVICE FUNCTIONS
Service information for the drive can be shown on
display lines 3 and 4. Twenty-six different items can
TRIP (AUTO RESTART) means the drive is be accessed. Included in the data are counters that
programmed to restart automatically after the fault is tabulate operating hours, power ups and trips; fault
removed. The number of automatic reset attempts logs that store drive status values present at the 20
may be continuous or limited to a programmed most recent events that stopped the drive; and drive
number of attempts. This will change to TRIP (RESET) nameplate data. The service information is accessed
if the selected number of automatic reset attempts is by displaying items in the drive's 600s parameter
exceeded. group.
TRIP (RESET) requires resetting the drive prior to
operation after a fault is cleared. The drive can be FREQUENCY
reset manually by pressing the reset key on the
keypad, a digital input, or a serial bus command. For
VLT 5000 series drives, the stop and reset key are
the same. If the stop/rest key is used to reset the
0.0Hz
604 OVER TEMP'S
SETUP
1
Line 3
drive, the start key must be pressed to initiate a run
command in either local or remote. 0003
Line 4
TRIPLOCK (DISC> MAINS) requires that the main AC
input power to the drive must be disconnected long
enough for the display to go blank. The fault condition
must be removed and power reapplied. Following MENU Parameter settings are displayed by
power up, the fault indication will change to TRIP pressing the [MENU] key on the LCP
(RESET) and allow for manual, digital, or serial bus keypad.
reset.
Line 2 displays alarm and the associated number while +
Use the [+] and [-] keys on the LCP
line 3 identifies the alarm in plain language.
– keypad to scroll through parameters.
Output Signals
The drive also produces output signals that are carried
through either the RS-485 serial bus or terminals 42
and 45. Output terminals 42 and 45 operate in the
same manner as the inputs. These terminals can be
programmed for either a variable analog signal in mA
or a digital signal (0 or 1) in 24 VDC. In addition, the
terminals can provide a pulse reference of 0 to 32,000
pulses. Output analog signals generally indicate the
drive frequency, current, torque and so on to an
external controller or system. Digital outputs can be
control signals used to open or close a damper, for
example, or send a start or stop command to auxiliary
equipment.
Figure 1-1. Control Terminals Additional terminals are 01, 02, and 03, which are a
Form C relay output. Terminals 04 and 05 are a 1 A
low voltage relay output.
Terminals 12 and 13 provide 24 VDC low voltage
power, often used to supply power to the digital input
Input Signals terminals (16-33). Those terminals must be supplied
The drive can receive two types of remote input with power from either terminal 12 or 13, or from a
signals: digital or analog. Digital inputs are wired to customer supplied external 24 VDC power source.
terminals 16, 17, 18, 19, 20 (common), 27, 29, 32, Improperly connected control wiring is a common
and 33. Analog inputs are wired to terminals 53, 54, service issue for a motor not operating or the drive
and 55 (common), or terminal 60. not responding to a remote input.
60 Programmable 0 to 20 mA or 4 to 20
mA, analog current input, R = 188 Ω.
Used for reference or feedback
signals.
61 RS-485 common.
power card
Located on
Correct grounding
Control cables and cables for serial communication must be fitted
with cable clamps at both ends to ensure the best possible electrical
connection.
Incorrect grounding
Do not use twisted cable ends (pigtails) since these increase shield
impedance at high frequencies.
GENERAL In its basic form, the drive can be divided into four
This section is intended to provide an operational over main sections: rectifier, intermediate circuit, inverter,
view of the drive’s main assemblies and circuitry. With and control and regulation (see Figure 2-1).
this information, a repair technician should have a
To provide an overview, the main drive components
better understanding of the drive's operation and aid
will be grouped into three categories consisting of
in the troubleshooting process.
the control logic section, logic to power interface,
The VLT series drives covered in this manual are very and power section. In the sequence of operation
similar in design and construction. For the purpose description, these three sections will be covered in
of troubleshooting, two main differences exist. First, greater detail while describing how power and control
the control card and LCP for the VLT 5000 series signals move throughout the drive.
differs from that of the other three series. Second,
the power section is rated differently in a constant
torque drive (VLT 5000) versus a variable torque drive.
Logic Section
The power section of a 125 hp VLT 5000 series is The control card contains most of the logic section
similar to that of a 150 hp in the other three series, (see Figure 2-2). The primary logic element of the
and so on. To simplify the discussion, this section control card is a microprocessor, which supervises
refers to the constant torque VLT 5000 drives, and controls all functions of drive operation. In
except where necessary to detail specific addition, separate PROMs contain the parameters
variations. to provide the user with programmable options. These
parameters are programmed to enable the drive to
meet specific application requirements. This data is
DESCRIPTION OF OPERATION then stored in an EEPROM which provides security
An adjustable frequency drive is an electronic during power-down and also allows the flexibility to
controller that supplies a regulated amount of AC change the operational characteristics of the drive.
power to a standard three phase induction motor in
A custom integrated circuit generates a pulse width
order to control the speed of the motor. By supplying
modulation (PWM) waveform which is then sent to
variable frequency and voltage to the motor, the drive
the interface circuitry located on the power card.
controls the motor speed, or maintains a constant
speed as the load on the motor changes. The drive
can also stop and start a motor without the Local
Control
mechanical stress associated with a line start. Panel
DATA
MICROPROCESSOR
ADRESS
EE
VVC D ANALOG
RAM PROM
PR
PLUS A INPUTS
O
M
2
CONTROL POWER
FEEDBACK
POWER
DIGITAL
INPUTS
1
T1
T2
T3 D ANALOG
A OUTPUTS
DIGITAL
CHANNEL
Power Section
RELAY
Control Logic
T1
T2
T3
Rectifier Section
When input power is first applied to the drive, it enters When the DC bus capacitors are fully charged, the
through the input terminals (L1, L2, L3) and on to the voltage on the DC bus will be equal to the peak
disconnect or/and RFI option, depending on the unit's voltage of the input AC line. Theoretically, this can be
configuration (see Figure 2-4). If equipped with calculated by multiplying the AC line value by 1.414
optional fuses, these fuses (FU1, FU2, FU3) limit (VAC x 1.414). However, since AC ripple voltage is
damage caused by a short circuit in the power present on the DC bus, the actual DC value will be
section. The SCRs, in the combined SCR/Diode closer to VAC x 1.38 under unloaded conditions and
modules, are not gated so current can travel to the may drop to VAC x 1.32 while running under load.
rectifier on the soft charge card. Additional fuses For a drive connected to a nominal 460 V line, while
located on the soft charge card provide protection in sitting idle, the DC bus voltage will be approximately
the event of a short in the soft charge or fan circuits. 635 VDC.
Three phase power is also branched off and sent to
As long as power is applied to the drive, this voltage
the power card. It provides the power card with a
is present in the intermediate circuit and the inverter
reference of the main supply voltage and provides a
circuit. It is also fed to the Switch Mode Power Supply
supply voltage for the cooling fans.
(SMPS) on the power card and is used for generating
During the charging process, the top diodes of the all other low voltage supplies.
soft charge rectifier conduct and rectify during the
positive half cycle. The diodes in the main rectifier
conduct during the negative half cycle. The DC
voltage is applied to the bus capacitors through the
soft charge resistor. The purpose of charging the DC
bus through this resistor is to limit the high inrush
current that would otherwise be present.
Positive temperature coefficient (PTC) resistors
located on the soft charge card are in series with the
soft charge resistor. Frequent cycling of the input
power or the DC bus charging over an extended time
can cause the PTC resistors to heat up due to the
current flow. Resistance of the PTC device increases
with temperature, eventually adding enough
resistance to the circuit to prevent significant current
flow. This protects the soft charge resistor from
damage along with any other components that could
be damaged by continuous attempts to charge the
DC bus.
When the DC bus reaches approximately 400 VDC,
the low voltage power supplies are activated. After a
short delay, an inrush enable signal is sent from the
control card to the power card SCR gating circuit.
The SCRs are automatically gated when forward
biased, acting, as a result, similar to an uncontrolled
rectifier.
Regardless of the heatsink temperature, the fans are started Specific Card Connections
shortly after main input power is applied to the drive. If the Connector FK102, terminals 104, 105 and 106 located on
heatsink temperature is below 86°F (30°C), the fans will turn the power card, provide for the connection of an external
off after a short interval. At a heatsink temperature of greater temperature switch. The input could be used to monitor the
than 113°F (45°C), the fans are switched on at low speed. temperature of an external brake resistor. Two input
This equates to approximately 200 VAC applied to the fans. configurations are possible. A normally closed switch may
At a heatsink temperature of more than 140°F (60°C), 230 be connected between terminals 104 and 106 or a normally
VAC is applied to the fans to obtain full speed. When the open switch between terminals 104 and 105. Should the
heatsink temperature returns to less than 131°F (55°C), the input change states, the drive would trip on an Alarm 29,
fans return to low speed. Below 86°F (30°C)the fans switch Overtemperature. The input SCRs would also be disabled
off. to prevent further energy from being supplied to the DC
bus. If no such input is used, or the normally open
Since the internal ambient temperature is maintained by
configuration is selected, a jumper must be installed between
one or more 230 VAC fans, the transition between low
terminals 104 and 106.
and high speeds also occurs if the internal ambient rises,
regardless of heatsink temperature. The internal ambient Connector FK103, terminals 100, 101, 102, and 103
temperature sensor is located on the power card. If the located on the power card, provide for the connection of
internal temperature rises to greater than 95°F (35°C), the 230 VAC to allow powering the AC cooling fans from an
fans will switch to high speed, regardless of the heatsink external source. This is required when the drive is used in
temperature. If the internal ambient temperature returns a load sharing application where no AC power is provided
to 86°F (30°C) and the heatsink temperature remains below to the main input terminals. To make use of this provision,
140°F (60°C), the fans will return to low speed. the jumpers would be removed from terminals 100 and
102, 101 and 103. The auxiliary 230 VAC power supply
The fans switch to low speed should a heatsink over
would be connected to terminals 100 and 101.
temperature trip occur. In addition, regardless of any
temperature, when the load current on the drive reaches There are two FK100 terminals, one on the interface card
60% of its continuous rating the fans are switched on at and one on the power card.
low speed and then follow the temperatures as listed above.
The power card FK100, terminals 1, 2, and 3, provide
access to auxiliary relay 1. This is a form C set of contacts,
Load Sharing meaning one normally open and one normally closed
Units with the built-in load sharing option contain terminals contact on a single throw. The contacts are rated for a
89 (+) DC and 88 (-) DC. Within the drive, these terminals maximum of 240 VAC, 2 Amps and a minimum of 24VDC,
connect to the DC bus in front of the DC link reactor and 10mA or 24 VAC, 100mA. The relay can be programmed
bus capacitors. via parameter 323 to indicate drive status.
The use of the load sharing terminals can take on two The interface card FK100, terminals 35 and 36, accept 24
different configurations. VDC from an external source, if the drive is so equipped.
This input provides control power to keep the control logic
In one method, the terminals are used to tie the DC bus and any installed options powered up and communicating
circuits of multiple drives together. This allows for the even with the main supply power removed from the drive.
possibility of one drive that is in a regenerative mode to share This is particularly useful for maintaining a bus
its excess bus voltage with another drive that is in the communications network while some drives are not being
motoring mode. When applied correctly, this can reduce powered by the mains.
the need for external dynamic brake resistors while also
saving energy. In theory, the number of drives that can be Terminal positions on the power card labeled MK400,
connected in this way is infinite, however, the drives must MK103, and FK101 are reserved for future use.
be of the same voltage rating. In addition, depending on the
size and number of drives, it may be necessary to install DC
Drive display Warnings, alarms, drive status, fault history and many other important
items are available through the display on the local control panel of drive.
Input power Check for loose connections. Check for proper fusing. Check for blown
wiring fuses.
Output to motor Check for loose connections. Check for switching components in output
wiring circuit. Check for faulty contacts in switch gear.
Grounding The drive requires a dedicated ground wire from its chassis to the
building ground. It is also suggested that the motor be grounded to the
drive chassis as well. The use of conduit or mounting of the drive to a
metal surface is not considered a suitable ground. Check for good
ground connections that are tight and free of oxidation.
Control wiring Check for broken or damaged wires and connections. Check the voltage
source of the signals. Though not always necessary depending on the
installation conditions, the use of shielded cable or a twisted pair is
recommended. Ensure the shield is terminated correctly. Refer to the
section on grounding shielded cables in Section 1.
Programming Check that drive parameter settings are correct according to motor,
application, and I/O configuration.
Motor Check nameplate ratings of motor. Ensure that motor ratings coincide
with drives. Check that drive's motor parameters (102 – 106) are set
according to motor ratings.
Cable routing Avoid routing motor wiring, AC line wiring, and signal wiring in parallel. If
parallel routing is unavoidable, try to maintain a separation of 6 - 8 inches
between the cables or separate them with a grounded conductive
partition. Avoid routing cables through free air.
Auxiliary Look for auxiliary equipment, switches, disconnects, or input fuses/circuit
equipment breakers that may reside on input power side of drive or output side to
motor. Examine operation and condition of these items as possible
causes for operational faults. Check function and installation of pressure
sensors or encoders (etc.) used for feedback to drive.
Drive cooling Check operational status of all cooling fans. Check door filters on NEMA
12 (IP54) units. Check for blockage or constrained air passages.
Drive interior Drive interior must be free of dirt, metal chips, moisture, and corrosion.
Check for burnt or damaged power components or carbon deposits that
were the result of a catastrophic component failure. Check for cracks or
breaks in the housings of power semiconductors, or pieces of broken
component housings loose inside the unit.
EMC Check for proper installation with regard to electromagnetic capability.
considerations Refer to the drive instruction manual and Section 4 of this manual for
further details.
Vibration Though somewhat subjective look for an unusual amount of vibration that
the drive may be subjected to. The drive should be mounted solidly or the
use of shock mounts employed.
Environmental Under specific conditions these units can be operated within a maximum
conditions ambient of 50°C (122°F). Humidity levels must be less than 95% non-
condensing. Check for harmful airborne contaminates such as sulfur
based compounds.
Proper These drives require a top and bottom clearance of nine (9) inches to
clearance ensure proper air flow for cooling. Drives with exposed heat sinks out the
back of the drive must be mounted on a flat solid surface.
Check for mechanical overloading on motor shaft. This fault results in a Trip Locked condition.
Manual reset is possible after the ETR counter has See Drive and Motor Application in Section 4 for more
counted to zero. information.
WARNING/ALARM 11 ALARM 14
MOTOR THERMISTOR EARTH FAULT
The motor thermistor function has been activated in The unit has sensed output leakage current sufficient
parameter 128 and a thermistor is connected to either enough to determine that there is a ground fault in
terminal 53 or 54 and programmed as such in the motor or motor wiring. This fault results in a Trip
parameter 308 or 311. Parameter 128 provides a Locked condition.
choice of warning or alarm. Manual reset is possible. Short circuit to ground in motor or motor wiring, or
This warning or trip occurs when the input to terminal faulty current sensor.
53 or 54 is more than 3K Ohms impedance between Measure resistance to ground of motor leads with
that terminal and terminal 50 or when the voltage to megohmmeter to check for earth faults.
the selected terminal is greater than 8 VDC. This could
indicate an overheated motor. It is also possible that Perform current sensor test (section 5).
the connection has been broken. See Internal Drive Problems in Section 5.
Check for overheated motor (if Thermistor function is
being used). Check for open connection by measuring
voltage between corresponding terminal and terminal
55. A reading of greater than 8 VDC indicates an open
connection.
This is due to a phase to phase short circuit in motor AMA Function has been completed successfully.
or motor wiring. No corrective action is needed. This alarm is displayed
Check motor and cabling for shorts. upon completion of AMA to indicate a requirement to
reset the drive after performing AMA.
WARNING/ALARM 17
STD BUS TIMEOUT ALARM: 22
Indicates the serial communication with the VLT has AUTO MOT ADAPT FAIL
failed and the time out function has been activated. Auto-optimization not OK. The automatic motor tuning
The delay time programmed determines how long function failed. The possible causes as shown in the
the warning will be present before a trip, provided display are listed below. The numbers in brackets will
“stop and trip” has been selected. be logged as the value in parameter 617.
Manual reset is possible. Check settings of p. 102 - 106, and restart AMA.
Loss of serial communication signal due to faulty wiring In case of non-standard motor, set p. 107 to “Enable
or communication equipment (PC, PLC, RS232/485 RS” and restart AMA.
Adaptor, etc.) [0] CHECK P .103, 105
P.103,
Check connections on serial communication cable. AMA function was unable to be carried out due to
Check operation of communication equipment. incorrect settings or incorrect results of AMA tests.
Torque Limit, Current Limit, and Parameter 107 activates the automatic motor
Unstable Motor Operation adaptation (AMA) function. When AMA is performed,
Excessive loading of the drive may result in warning the drive measures the electrical characteristics of the
or tripping on torque limit, over current, or inverter motor and sets various drive parameters based on
time. This is not a concern if the drive is properly sized the findings. Two key parameter values set by this
for the application and intermittent load conditions function are stator resistance and stator reactance,
cause anticipated operation in torque limit or an parameters 108 and 109. If unstable motor operation
occasional trip. However, nuisance or unexplained is experienced and AMA has not been performed, it
occurrences may be the result of improperly setting should be done. AMA can only be performed on single
specific parameters. The following parameters are motor applications within the programming range of
important in matching the drive to the motor for the drive. Consult the instruction manual for more on
optimum operation. These setting need careful this function.
attention, particularly for the selectable torque drives Parameters 108 and 109, as stated, should be set by
of the VLT 5000 series. For the VLT 4000/6000/8000 the AMA function or left at the factory default values.
series, torque settings are constant. Never adjust these parameters to random values even
Parameters 100 and 101 set the mode in which though it may seem to improve operation. Such
the drive will operate. adjustments can result in unpredictable operation
under changing conditions.
Parameters 102 through 107 match the drive to Parameter 221, Torque Limit, sets the limit for drive
the motor and adapt to the motor characteristics. torque. The factory setting is 160% for VLT 5000 series
and 110% for VLT 4000/6000/8000 series and will
Parameters 221 and 409 set the torque control vary with motor power setting. For example, a drive
features of the drive for the application. programmed to operate a smaller rated motor will yield
a higher torque limit value than the same drive
Parameter 100, Configuration, sets the drive for open programmed to operate a larger size motor. It is
or closed loop operation or torque mode operation. important that this value not be set too low for the
In a closed loop configuration,a feedback signal requirements of the application. In some cases, it may
controls the drive speed. The settings for the PID be desirable to have a torque limit set at a lesser value.
controller play a key role for stable operation in closed This offers protection for the application in that the
loop, as described in the operator's manual. In open drive will limit the torque. It may, however, require
loop, the drive calculates the torque requirement higher torque at initial start up. Under these
based on current measurements of the motor. circumstances, nuisance tripping may occur.
Parameter 101, Torque Characterisitcs, for the VLT Parameter 409, Trip Delay Torque, works in
5000 series, sets the drive for constant or variable conjunction with torque limit in the VLT 5000 series.
torque operation. It is imperative that the correct This parameter selects the length of time the drive
torque characteristic is selected, based on the operates in torque limit prior to a trip. The factory
application. If, for example, the load type is constant default value is off. This means that the drive will not
torque, such as a conveyor, and variable torque is trip on torque limit, but it does not mean it will never
selected, the drive may have great difficulty starting trip from an overload condition. Built into the drive is
the load, if started at all. Consult the factory if uncertain an internal inverter thermal protection circuit. This
about the torque characteristics of an application. circuit monitors the output load on the inverter. If the
Parameters 102 through 106 configure the drive for load exceeds 100% of the continuous rating of the
the connected motor. These are motor power, voltage, drive, a timer is activated. If the load remains excessive
frequency, current, and rated motor speed. Accurate long enough, the drive will trip on inverter time.
setting of these parameters is very important. Enter Adjustments cannot be made to alter this circuit.
the motor data requred as listed on the motor Improper parameter settings effecting load current can
nameplate. For effective and efficient load control, the result in premature trips of this type. The timer can be
drive relies on this information for calculating the output displayed.
waveform in response to the changing demands of
the application.
Filter reactor
AC Line Motor
IGBT
Filter capacitor
VFD
Motor
VLT
VLT
Stray capacitance
VLT
Stray capacitance
AC Line
MK101
MK103
Current scaling card
MK105(A) +DC
Interface Card
MK105(B) -DC
MK400
FK100
FK101
FK102
MK109 MK100
MK106
FK103 MK107
Power Card
NOTE
If unit has fused disconnect option, make
test connections L1, L2, and L3 to output
(drive) side of disconnect. Do not unplug
connector.
2. Connect negative (–) meter lead to 2. Connect negative (–) meter lead to
terminals L1, L2, and L3 in turn. terminals L1, L2 and L3 in turn. Each
reading should show a diode drop.
Each reading should show infinity. The meter will start
at a low value and slowly climb towards infinity due to Incorrect Reading
capacitance within the drive being charged by the With the Part III test connection, the diodes in the
meter. SCR/Diode modules are forward biased as well as
the lower diodes in the soft charge rectifier. The meter
Incorrect Reading reads the diode drops. If a short circuit exists it would
With the Part I test connection, the SCRs in the SCR/ be possible that either the diodes in the SCR/Diode
Diode modules are reverse biased so they are blocking modules or the lower diodes in the soft charge rectifier
current flow. If a short circuit exists, it would be are shorted. To isolate between SCRs or the soft
possible that either the SCRs or the diodes in the soft charge rectifier, perform the Soft Charge Rectifier Test.
charge rectifier are shorted. To isolate between SCRs
or the soft charge rectifier, perform the Soft Charge Although an open reading is possible, it is unlikely since
Rectifier Test. that indicates that both the diodes in the SCR/diode
modules and the lower diodes in the soft charge
rectifier are both open. Should such a result occur
5.1.1.3 Main Rectifier Circuit Test Part II perform the Soft Charge Rectifier Test to isolate
1. Reverse meter leads by connecting between the two.
negative (–) meter lead to positive (+) DC 5.1.1.5 Main Rectifier Circuit Test Part IV
bus connector MK105 (A) on power 1. Reverse meter leads by connecting
card. negative (–) meter lead to negative (-)
DC bus connector MK105 (B) on power
2. Connect positive (+) meter lead to L1, card.
L2, and L3 in turn. Each reading should
show a diode drop. 2. Connect positive (+) meter lead to L1,
L2 and L3 in turn. Each reading should
Incorrect Reading show infinity.
With the Part II test connection, even though the SCRs
in the SCR/Diode modules are forward biased by the Each reading should show infinity. The meter will start
meter, current will not flow through the SCRs without at a low value and slowly climb toward infinity due to
providing a signal to their gates. The upper diodes in capacitance within the drive being charged by the
the soft charge rectifier are forward biased so the meter.
meter reads the voltage drop across those diodes.
Incorrect Reading
If an open reading were present, it would indicate the With the Part IV test connection, the diodes in the
upper diodes in the soft charge rectifier are open. It SCR/Diode modules are reversed biased as well as
could also indicate that one or more of the soft charge the lower diodes in the soft charge rectifier. If a short
fuses are open. It could further indicate that the soft circuit exists it would be possible that either the diodes
charge resistor is open. To isolate between the three in the SCR/Diode modules or the lower diodes in the
possibilities, perform the Soft Charge Fuse Test and soft charge rectifier are shorted. To isolate between
Soft Charge Rectifier Test. SCRs or the soft charge rectifier, perform the Soft
A short circuit reading indicates either one or more of Charge Rectifier Test.
the upper soft charge rectifier diodes are shorted or
the SCRs are shorted in the SCR/Diode module. To
isolate between SCRs or the soft charge rectifier,
perform the Soft Charge Rectifier Test.
Do not remove the soft charge card completely or An incorrect reading here indicates the soft charge
unplug any connectors not called out. Doing so will rectifier is shorted. The rectifier is not serviced as a
break the continuity path of these measurements and component. Replace the entire soft charge card in
may result in a false interpretation of a failure. accordance with the disassembly procedures in
1. Extract soft charge card far enough to Section 6.
access connectors. 7. Reverse meter leads with negative (-)
meter lead to negative (-) MK3 (C).
2. Disconnect DC cable at connector MK3. Connect positive (+) meter lead to MK1
terminals R, S, and T in turn. Each
Since the rectifier test requires the soft charge resistor reading should show open.
to be in the circuit, verify the resistor is good before
proceeding. If all tests indicate correctly while isolating between
3. Measure resistance between pins A and the SCR/Diode modules and the soft charge card,
B of connector MK4 on soft charge card. the SCR/Diode modules are suspect. Before
It should read 27 ohm (+/- 10%). A reconnecting the cable at MK3, return to the Main
shorted reading, an open reading (infinity) Rectifier tests and repeat those tests. Put the power
or a reading of less than 24 ohms card temporarily back in place to retest the main
indicates a defective soft charge resistor. rectifier. Replace any defective assemblies in
Replace resistor in accordance with accordance with the disassembly procedures in
disassembly procedures in Section 6. Section 6.
Continue tests.
Incorrect Reading
An incorrect reading would indicate a defective fan
transformer. Replace the fan transformer.
When finished, be sure to reconnect CN2.
Figure 5-4. Fan Transformer and Fuse Location
First test for the presence of the DC bus. 1. Remove power to drive and ensure DC bus
is fully discharged by measuring voltage at
1. Using a voltmeter, read DC bus voltage at power card connector MK105 (A) with
power card connector MK105 (A) with respect to MK105 (B).
respect to MK105 (B). Meter should indicate
approximately 470 VDC to 730 VDC,
depending on line voltage supplied to drive. ! CAUTION
If DC power supply fuse is open (blown),
2. If voltage is correct proceed to set 3. If it is not possible to detect the presence
voltage is present but out of range, proceed of bus voltage at these terminals. If
to DC Under Voltage test. If voltage is at zero, uncertain, wait 15 minutes to allow DC
proceed to Zero DC Bus Voltage test. bus to fully discharge.
3. Test remaining power supplies. Insert signal 2. With ohmmeter set on diode scale or
test board into interface card connector Rx100, measure from power card
MK104 connector MK105 (A) to any bus bars
coming from DC inductor. Bus bars are
4.. Connect negative (-) meter lead to terminal 4 visible at lower edge and beneath power
(common) of signal board. With positive (+) card mounting bracket. Depending on bus
meter lead check the following terminals on bar read, look for a diode drop or complete
signal board. short. In either case this indicates a fuse is
in the circuit providing a path for continuity.
Terminal Supply V oltage Range
Voltage An open reading indicates open fuse.
11 +18V 16.5 to 19.5 VDC
12 -18V -16.5 to -19.5 VDC If the fuse is open, it indicates a failure of the power
23 +24V 23 to 25 VDC supplies on the power card. The power card and
24 +5V 4.75 to 5.25 VDC fuse require replacement. If the fuse checks good,
there may be a problem with the soft charge circuitry.
In addition, the signal test board contains three LED Proceed to the static checks of the soft charge and
indicators that indicate the presence of voltage as rectifier circuits earlier in this section.
follows:
With a reading of 0 VDC and proper line power applied A2 > 0.40 A
to the drive, it would be likely that the input at power
card terminal FK102 has caused the SCRs to be T1> 300 µs
disabled. Given the connection at FK102 has been
Given all the other tests above were successful, a
verified the control card would be suspect. Check the
missing gate signal indicates the power card is
inrush signal as follows.
defective. Replace the power card in accordance
7. Connect positive (+) meter lead to with the disassembly procedures in Section 6.
terminal 7 of signal board.
A distorted signal may be due to a defective gate on
that particular SCR that is loading down the supply.
A reading of 0 VDC indicates the inrush signal is active
Replace the SCR/Diode module which corresponds
and the SCRs are being gated. A reading of 5 VDC
to the incorrect gate signal reading.
indicates the inrush signal is inactive and the SCRs are
not gated.
If the voltage is balanced but the current is not, this The output current should be balanced from phase
indicates the motor is drawing an uneven load. This to phase and no phase should be more than 2 to 3%
could be the result of a defective motor, a poor different from another. If the above tests are successful,
connection in the wiring between the drive and the the drive is operating normally.
motor, or, if applicable, a defective motor overload.
3. If a greater imbalance exists than
If the output current is unbalanced as well as the described above, disconnect motor
voltage, the drive is not gating the output properly. leads and repeat voltage balance test.
This could be the result of a defective power card,
gate drive, connections between the gate drive card Since the current will follow the voltage, it is necessary
and IGBTs, or the output circuitry of the drive to isolate between a load problem and a drive problem.
improperly connected. Should a voltage imbalance in the output be detected
NOTE with the motor disconnected, it is necessary to test
Use an analog volt meter for monitoring the gate drive circuits for proper firing. Proceed to the
output voltage. Digital volt meters are gate drive signals test (5.2.9).
sensitive to waveform and switching If the voltage was balanced but the current imbalanced
frequencies and commonly return when the motor was connected, then the load is
erroneous readings. suspect. There could be a faulty connection between
the drive and motor or a defect in the motor itself.
The initial test can be made with the motor connected Look for bad connections at any junctions of the
and running its load. If suspect readings are recorded output wires including connections made to
then the motor leads may have to be disconnected contactors and over loads. Also, check for burned or
to further isolate the problem. open contacts in such devices.
1. Using a volt meter, measure AC output
voltage at drive motor terminals 96 (U),
97 (V), and 98 (W). Measure phase to
phase checking U to V, then U to W,
and then V to W.
A simple test to check for the presence of the gate 5. Connect free end of Test Cable into MK105.
signals can be performed with a DVM, however to
actually check the waveforms an oscilloscope is 6. Connect SCR gate shorting plug (included
required. with test cable 176F8437) into cable that
! CAUTION
was removed from MK100.
Disable DC bus when performing this test Located on the gate drive card near each gate signal
with Test Cable p/n 176F8437. Failure to do lead is a 3 pin test connector. These are labeled
so could result in damage to drive if probe MK250, MK350, MK450, MK550, MK650, MK750,
is inadvertently connected to wrong pins. and, if the drive is equipped with a brake option,
Additionally, AC mains bus bars are in MK850.
close proximity to these test points.
Exercise caution when working close to For the sake of clarity, refer to the 3 pins as one, two,
high voltage components. and three, reading left to right. Pins 1 and 2 of each
connector are in parallel with the gate drive signal
Prior to beginning the tests, ensure that power is sent to the IGBTs. Pin 1 is the signal and pin 2 is
removed from the unit and that the DC Bus capacitors common.
have been discharged. 7. Reconnect AC power to drive.
Check for the presence of DC bus voltage by measuring
power card connector MK105 (A) with respect to MK105 8. In stop mode, apply power to drive.
(B). The voltage should be zero (0) before proceeding.
9. Measure pins 1 and 2 of each test
1. Follow procedure in Section 6 for soft connector. Each reading should be
charge card removal and disengage soft approximately –9 VDC, indicating all IGBTs
charge card far enough to disconnect are tuned off.
cable plugged into MK3.
10. Apply run command to drive and 30 Hz
2. Connect one end of Test Cable into MK3. reference.
CONTINUED ON NEXT PAGE
2. Ensure that motor check, pre- 12. Run drive with a zero speed reference.
magnetizing, DC hold, DC brake, or other
parameter setups are disabled that create 13. In turn measure AC voltage at
a holding torque while at zero speed. terminals 1, 2, and 3 of signal test
Current displayed will exceed 1 to 2 board. These terminals correspond
amps if such parameters are not with current sensor outputs U, V, and
disabled. W, respectively. Expect a reading near
zero volts but no greater than 15mv.
3. Run drive with a zero speed reference.
Note output current reading in display. If the control card parameters are setup to provide
Display should indicate approximately 1 holding torque while at zero speed, the current
to 2 amps. displayed will be greater than expected. To make this
test disable such parameters.
If the current is greater than 1 to 2 amps and a current
producing parameter is not active, the test will to be The current sensor feedback signal at this point in
made again with the motor leads disconnected. the circuit will read approximately 400mv at 100%
drive load so any reading above 15mv while the drive
4. Remove power from drive. Monitor DC is at zero speed has a negative effect on the way the
bus voltage at power card connector drive interprets the feedback signal.
MK105 (A) and (B) to ensure bus is fully
discharged. A reading of greater than 15mv suggests that the
corresponding current sensor be replaced. See the
5. Remove output motor leads from disassembly instructions in Section 6.
terminals U, V, and W.
3. If line voltage is present at input of drive but 2. Install signal test board into interface
not at MK106 of power card, conduct static connector MK104.
test of soft charge fuses (5.1.1).
3. Reapply power to drive.
4. If voltage is present at MK106, check
voltage at fan transformer read from 4. Connect negative (-) meter lead of a
connector CN2 located near transformer. voltmeter to signal board terminal 4
With a volt meter, read AC voltage at CN2 (common).
pins 1 and 3. Voltage should correspond to
main AC line voltage applied to drive. 5. With positive (+) meter lead check signal at
terminal 6 of signal board. Meter should
5. If voltage is not present, ensure jumpers are read zero (0) volts with fans commanded to
in place at power card connector FK103. run, 5 VDC if control card fans off.
Otherwise connect an external source of
power to terminal FK103 for fan supply 6. Verify cooling fans sequence of operation to
voltage. ensure they should be running. In addition,
signal board contains a fan test switch.
If the jumpers are in place or an auxiliary supply is When switched on fans should start and run
connected and powered but no voltage is present at at high speed.
the fan transformer connector CN2, the power card
is likely defective. Replace the power card in The signals at terminals 5 and 10 of the signal board
accordance with the disassembly instructions in determine fan speed. See Section 7 for more on those
Section 6. signals. In addition, if a heat sink overtemperature trip
has occurred, the fans will automatically be switched
5.2.13.2 T ransformer Output
Transformer to high speed.
If the appropriate voltage is present at CN2 pins 1
and 3, next check the output of the transformer. Prior Given the fact that the fans should be running, if the
to making this test, ensure the fan transformer fuse signal at terminal 6 is correct and the fan test switch
located next to the transformer is good. activates the fan, the control card is defective.
Otherwise the power card is defective. Replace the
1. With a volt meter, measure AC voltage from appropriate assembly in accordance with the
CN2 terminal 1 to terminal 2. Voltage disassembly instructions in Section 6.
should equal 66% of main AC supply
voltage applied to drive (or that of auxiliary
supply). If voltage is incorrect, replace fan
transformer.
12MA 1
DIGITAL INPUT
REMOTE RUNNING
00101000 SETUP
1
If the desired signal is not present in the display, the
REMOTE RUNNING problem may be either in the external control wiring
to the drive or a faulty control card. To determine the
fault location, use a volt meter to test for a signal at
the control terminals.
If the desired signal is not present in the display, the
problem may be either in the external control wiring to Verify the reference voltage power supply is correct
the drive or a faulty control card. To determine the fault as follows.
location, use a volt meter to test for voltage at the control 1. With a voltmeter measure voltage at
terminals. control card terminal 50 with respect to
Verify the control voltage power supply is correct as terminal 55. Meter should read
follows. between 9.2 and 11.2 VDC.
1. With a voltmeter measure voltage at If the 10 V supply voltage is not present, conduct
control card terminal 12 and 13 with the Control Card Voltage Test earlier in this section.
respect to terminal 20. Meter should read
between 21 and 27 VDC. If the 10 volts is present proceed with checking the
individual inputs as follows.
If the 24 V supply voltage is not present, conduct the 2. Connect (-) negative meter lead to
Control Card Test (5.2.15) earlier in this section. reference terminal 55.
If the 24 V is present proceed with checking the
individual inputs as follows. 3. Connect (+) positive meter lead to
desired terminal 53, 54 or 60.
2. Connect (-) negative meter lead to
reference terminal 20. For analog input terminals 53 and 54, a DC voltage
between 0 and +10 VDC should be read to match
3. Connect (+) positive meter lead to the analog signal being sent to the drive.
terminals 16, 17, 18, 19, 27, 29, 32, and For analog input terminal 60, a reading of 0.9 to 4.8
33 in turn. VDC corresponds to a 4 to 20ma signal.
Presence of a signal at the desired terminal should Note that a (-) minus sign preceding any reading
correspond to the digital input display reading. A reading above indicates a reversed polarity. In this case,
of 24 VDC indicates the presence of a signal. A reading reverse the wiring to the analog terminals.
of 0 VDC indicates no signal is present.
6.0 INSTRUCTIONS
! DANGER
Drives contain dangerous voltages when 6.1 Control Card Cassette
connected to line voltage. No 1. Remove control wiring by unplugging
disassembly should be attempted with control terminals (see Figure 6-1).
power applied. Remove power to drive
and wait at least 15 minutes to let drive 2. Remove grounding clamps by removing
capacitors fully discharge. Only a two screws holding each in place. Save
competent technician should carry out screws for reassembly.
service.
3. For NEMA 12 configurations, disconnect
ELECTROSTATIC DISCHARGE (ESD) cable between LCP and control card.
Many electronic components within the adjustable
frequency drive are sensitive to static electricity. 4. Unplug the two ribbon cables from side
Voltages so low that they cannot be felt, seen or of control card.
heard can reduce the life, affect performance, or
completely destroy sensitive electronic components. 5. Loosen two captive screws to free
cassette (T20 Torx).
! CAUTION 6. Slide cassette free from mounting tabs.
Use proper electrostatic discharge (ESD)
procedures when servicing drive to 7. Remove and replace control card in
prevent damage to sensitive accordance with instructions included
components. with replacement card.
Control card
Captive screws
(Step 5)
Grounding clamps
(Step 2)
Reinstall in reverse order of this procedure. Tighten Reinstall in reverse order of this procedure. Tighten
T25 screws and interface card standoffs to 20 in-lbs mounting screws and interface card standoffs to 20
(2.25 Nm). Card will initialize in service mode. Follow in-lbs (2.25 Nm).
instructions to enter data required.
6.4 Control Card/Power Card Mounting
Plate
1. Remove control card cassette and interface
6.3 Power Card card in accordance with procedures.
1. Remove interface card in accordance with
procedure. 2. Remove 4 mounting nuts (10mm).
2. Disconnect cables from connectors on 3. Disconnect all cabling from power card.
power card MK100, MK102, MK104,
MK105, MK106, MK107, MK109, MK110, 4. Remove optional wiring connections, as
FK100, and FK101. necessary, to free mounting plate.
3. Remove 2 interface card standoffs (8mm). 5. Lift plate free from chassis.
4. Remove power card by removing 5 Reinstall in reverse order of this procedure. Torque
mounting screws (T25 Torx) from standoffs. T25 mounting screws to 20 in-lbs (2.25 Nm).
MK103
Power card
MK102
PCA3
MK104
Power card mounting
Interface card standoff screw
MK105
Mounting plate
MK1
MK3
2. Disconnect MK102, MK103, MK104, and Figure 6-5. Upper and Lower Capacitor Bank
MK106 from gate drive card. Also remove Assemblies
MK105, for units with extended brake, and
MK101 for units with RFI filter. Note that
IGBT gate drive card can remain attached to
cap bank cover plate.
NOTE
On units with 2 capacitor banks mounted
one above the other, only upper cap bank
assembly is removed.
Retaining nuts
Soft Charge Resistor
(Step 5)
Retaining screws
(Step 4)
! CAUTION
Input terminal mounting plate weighs
approx. 15 - 60 lbs, depending on
mounted options.
SCR/Diode terminal
screw (Step 5)
SCR/Diode terminal
screw (Step 5)
Retaining nut
(Step 8)
Retaining screws
(Step 9)
REASSEMBLY
SCR/Diode module
Retaining nuts
(Step 6)
Retaining screws
(Step 5)
SCR/Diode module
SCR/Diode module
Current sensor
Current sensor
mounting screws (2)
Terminal
(Step 3)
Retaining nut
(Step 4)
Retaining nut
(Step 2)
Retaining nut
(Step 2)
Retaining screw
(Step 2)
Retaining screws
(Step 2)
AC input terminal
Snubber capacitor
SCR/Diode terminal
screw (Step 5)
IGBT output bus bar
retaining nut (Step 6)
SCR/Diode terminal
SCR/Diode input bus bar
screw (Step 5)
Retaining nut
(Step 9)
Retaining screws
(shown removed) (Step
8)
IGBT module
Retaining screws
(Step 11)
Retaining nut
(Step 7)
IGBT module
Retaining screw
(Step 13)
Retaining nut
(Step 6)
Do not remove
(Step 6)
IGBT module
IGBT output bus bar
(Step 7)
IGBT output bus bar retaining nut
(Step 7)
Figure 6-16. IGBT Module (1 of 2)
14.Clean heatsink surface with mild solvent or IGBT bus bar assembly (Step 8)
alcohaol solution.
Retaining nut (Step 8)
Snubber capacitor
(Step 9)
IGBT module
Retaining nut
(Step 11)
PCAs
Interface PCA: Control PCA to
PCA2 176F8300 SPARE,BCC INTERFACE PCA, VLT5122 Power PCA 1 1 1
Interface PCA: Control PCA to
PCA3 176F8301 SPARE,BCC INTERFACE PCA, VLT5152 Power PCA 1 1 1
Interface PCA: Control PCA to
PCA3 176F8302 SPARE,BCC INTERFACE PCA, VLT5202 Power PCA 1 1 1
Interface PCA: Control PCA to
PCA3 176F8303 SPARE,BCC INTERFACE PCA, VLT5252 Power PCA 1 1 1
Interface PCA: Control PCA to
PCA3 176F8304 SPARE,BCC INTERFACE PCA, VLT5302 Power PCA 1 1 1
Gate Drive PCA, conformal
PCA5 176F8305 SPARE.GATE DRIVE PCA,CC,VLT5122-5302 coated 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Softcharge PCA. Includes metal
PCA11 176F8306 SPARE,SOFTCHARGE PCA,CC,VLT5122-5302 mounting bracket 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
PCA8 176F8307 SPARE, HF PCA, VLT5122-5302 High Frequency PCA 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Current Scaling PCA. Installs
PCA4 176F8308 SPARE,I-SCALING PCA, VLT5122 on Power PCA 1 1 1
Current Scaling PCA. Installs
PCA4 176F8309 SPARE,I-SCALING PCA, VLT5152 on Power PCA 1 1 1
Current Scaling PCA. Installs
PCA4 176F8310 SPARE,I-SCALING PCA, VLT5202 on Power PCA 1 1 1
Current Scaling PCA. Installs
PCA4 176F8311 SPARE,I-SCALING PCA, VLT5252 on Power PCA 1 1 1
Current Scaling PCA. Installs
PCA4 176F8312 SPARE,I-SCALING PCA, VLT5302 on Power PCA 1 1 1
Power PCA does not include
PCA3 176F8313 SPARE,POWER PCA,CC,VLT5122-5302 the I-Scaling PCA 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Power PCA does not include
PCA3 176F8411 SPARE,POWER PCA,VLT5122-5302 the I-Scaling PCA 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Common Spares
Control PCA - VLT 5000
Process. Common to other
PCA1 176F1400 SPARE,PCA,CONTROL,VLT5000P Danfoss VLT drives 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Control PCA - VLT 5000
Process. Conformal coated.
Common to other Danfoss VLT
PCA1 176F1452 SPARE,CTRL CARD ASSY,PROC,CONF drives 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Control PCA - VLT 6000 HVAC.
Common to other Danfoss VLT
PCA1 176F1405 SPARE,PCA,CTRL CARD,VLT6000 drives 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Resistors
Heat sink thermistor. Includes
TH1 176F8321 SPARE,THERMISTOR ASSY,VLT5122-5302 cable assembly. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Soft charge resistor. Includes
R1+CBL26 176F8322 SPARE,SOFTCHARG RES ASSY,VLT5102-5302 cable assembly. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Capacitors
IGBT snubber caps mounted
C2,3,4,5,6,7 176F8323 SPARE,CAP,IGBT SNUBBER,VLT5122-5302 on IBGT modules. 3 3 3 3 3 3 6 6 6 6 6 6 6 6 6
Fuses
FU1,2,3 176F8334 SPARE,FUSE,SEMI,350A,500V,FWH Mains fuse. Package of 1 3 3 3 3 3 3
FU1,2,3 176F8335 SPARE,FUSE,SEMI,600A,500V,FWH Mains fuse. Package of 1 3 3 3 3 3 3 3 3 3
Disconnects
SW1 176F8345 SPARE,DISCONNECT SW,200A,600V,VLT5122-5152 Disconnect switch 1 1 1 1 1 1
176F8346 SPARE,DISCONNECT HANDLE,ROD,VLT5122-5152 Disconnect switch handle 1 1 1 1 1 1
SW1 176F8347 SPARE,DISCONNECT SW,400A,600V,VLT5252-5302 Disconnect switch handle 1 1 1 1 1 1 1 1 1
Disconnect switch/handle
176F8348 SPARE,DISCONNECT HANDLE,ROD,VLT5252-5302 connection rod 1 1 1 1 1 1 1 1 1
Bus Bars
IGBT bus bar and insulation
176F8376 SPARE,BB ASSY, IGBT,VLT5122-5152 assembly 1 1 1 1 1 1
IGBT bus bar and insulation
176F8377 SPARE,BB ASSY,IGBT-IND,VLT5202-5302 assembly 1 1 1 1 1 1 1 1 1
IGBT bus bar and insulation
176F8378 SPARE,BB ASSY,IGBT-CAP,VLT5202-5302 assembly 1 1 1 1 1 1 1 1 1
SCR bus bar and insulation
176F8379 SPARE,BB ASSY,SCR,VLT5122-5152 assembly 1 1 1 1 1 1
Refer to service manual for
176F8380 SPARE,BB,SCR,R\S\T,VLT5122-5152 location 3 3 3 3 3 3
Refer to service manual for
176F8381 SPARE,BB,SCR,MINUS,VLT5122-5152 location 2 2 2 2 2 2
Refer to service manual for
176F8382 SPARE,BB,DC LINK,MINUSVLT5202-5302 location 2 2 2 2 2 2 2 2 2
Refer to service manual for
176F8383 SPARE,BB,MOTOR,U/W,VLT5202-5302 location 2 2 2 2 2 2 2 2 2
Refer to service manual for
176F8384 SPARE,BB,MOTOR,V,VLT5202-5302 location 1 1 1 1 1 1 1 1 1
Refer to service manual for
176F8385 SPARE,BB,SCR,MINUS,1,VLT5202-5302 location 2 2 2 2 2 2
Enclosure Fabrications
Refer to service manual for
176F8412 SPARE,FAB,CHASSIS,RT SIDE,VLT5122-5152 location 1 1 1 1 1 1
Refer to service manual for
176F8413 SPARE,FAB,CHASSIS,LT SIDE,VLT5122-5152 location 1 1 1 1 1 1
Refer to service manual for
176F8414 SPARE,FAB,CHASSIS,RT SIDE,VLT5202-5302 location 1 1 1 1 1 1 1 1 1
Refer to service manual for
176F8415 SPARE,FAB,CHASSIS,LT SIDE,VLT5202-5302 location 1 1 1 1 1 1 1 1 1
Refer to service manual for
176F8416 SPARE,FAB,ENCL TOP KIT,IP21,VLT5122-5302 location 1 1 1 1 1
Refer to service manual for
176F8417 SPARE,FAB,ENCL TOP KIT,IP54,VLT5122-5302 location 1 1 1 1 1
Refer to service manual for
176F8418 SPARE,FAB,ENCL BOT,IP21,VLT5122-5303 location 1 1 1 1 1
Refer to service manual for
176F8419 SPARE,FAB,ENCL BOT,IP54,VLT5122-5303 location 1 1 1 1 1
Refer to service manual for
176F8420 SPARE,FAB,GLANDPLATE,VLT5122-5302 location 1 1 1 1 1 1 1 1 1 1
Refer to service manual for
176F8423 SPARE,FAB,IP00 DR,TOP,VLT5122-5152 location 1 1 1
Refer to service manual for
176F8424 SPARE,FAB,IP00 DR,TOP,VLT5202-5302 location 1 1 1
Refer to service manual for
176F8425 SPARE,FAB,IP00 DR,BOT,VLT5122-5152 location 1 1
Refer to service manual for
176F8426 SPARE,FAB,IP00DR,BOT,VLT5202-5302 location 1 1 1
Refer to service manual for
176F8427 SPARE,FAB,IP00 COVER,SIDE,VLT5122-5152 location 2 2
Refer to service manual for
176F8428 SPARE,FAB,IP00 COVER,SIDE,VLT5202-5302 location 2 2 2
Refer to service manual for
location. Does not include
176F8429 SPARE, FAB, IP20 COVER,TOP KIT,VLT5122-5302 176F8333 fan 1 1 1 1 1
176F8430 SPARE,CABLE CLAMP,60MM,VLT5122-5302 Power cable clamp 2 2 2 2 2 2 2 2 2 2
Power cable clamp bonding
176F8431 SPARE,EARTH BONDING PLATE plate 1 1 1 1 1 1 1 1 1 1
Service Tools
176F8437 SPARE,TOOL,PWR PCA SIG BOARD,VLT5122-5302 Power PCA signal test board
176F8439 SPARE,TOOL,PWR PCA PWR CABLES,VLT5122-5302 Power PCA test cables
9-1
9-2